Interconnecting member occupying less space in battery module and battery module comprising same

ABSTRACT

Provided is an interconnection member including: (a) a main cable made of a flexible flat cable (FFC) including a plurality of copper wires; (b) a plurality of terminal parts branched from the main cable and electrically connected to at least one of the copper wires of the main cable, the plurality of terminal parts being connected to the bus bars to sense voltages of the battery cells; (c) a connecting part formed on one-side end of the main cable, and electrically and mechanically connected to the PCB; and (d) at least one temperature sensing part branched from the main cable, adjacent to the connecting part, while sharing at least one of the copper wires of the main cable.

TECHNICAL FIELD

The present disclosure relates to an interconnection member occupying asmall space in a battery module, and a battery module including thesame.

BACKGROUND ART

Recently, secondary batteries that are chargeable and dischargeable arebeing widely used as energy sources for wireless mobile devices. Also,the secondary batteries have attracted considerable attention as powersources for electric vehicles (EVs), hybrid electric vehicles (HEVs),and plug-in hybrid electric vehicles (Plug-In HEVs), which have beenproposed as solutions to air pollution and the like caused by existinggasoline and diesel vehicles that use fossil fuels.

Small sized mobile devices use one or a couple of battery cells for eachdevice. On the other hand, medium and large sized devices such asvehicles use a battery pack in which a plurality of battery cells areelectrically connected to each other, due to requirement for high powerand large capacity.

Since it is preferable to manufacture the battery module as small andlightweight as possible, prismatic and pouch type batteries, which arecapable of being charged at a high degree of integration and arerelatively lightweight compared to their capacities, are being mainlyused as battery cells for the medium and large sized battery module.Particularly, much interest is recently focused on the pouch typebatteries, which use an aluminum laminate sheet as an exterior member,because of their characteristics such as light weight and lowmanufacturing costs.

In addition, the battery module has a configuration in which a pluralityof cells are combined, so since overvoltage, overcurrent, or overheatingoccurring in some of the battery cells may adversely affect safety andoperation efficiency of the battery module, there is a need for unitswhich detect and control the overvoltage, overcurrent, or overheating.

Therefore, sensing members such as a temperature sensor and a voltagesensor are connected to the battery cells in conjunction with a printedcircuit board to check and control the operation condition in real timeor at regular time intervals. However, the installation or theconnection of these sensing members makes the assembling process of thebattery module too complicated, and causes a danger of short-circuit dueto several wires for the sensing members.

In addition, as the application range of the secondary batteries isexpanded, the secondary batteries are used as power sources forvehicles. Thus, fastening units are required to maintain a stablecontact condition of the sensing members even when strong impact orvibration is applied thereto.

Aside from these units, a large number of members are generally requiredfor the mechanical fastening and electrical contacting, for constitutingthe battery module by using a plurality of battery cells with thesensing members. However, this makes the assembling process of thebattery cell too complicated, and increases the overall size of thebattery cell.

Therefore, there is a great need for a sensing member capable ofconstituting a battery module with a more compact structure, and abattery module including the sensing member.

DISCLOSURE OF THE INVENTION Technical Problem

The present disclosure provides solutions for the above-describedlimitations according to the related art and technical tasks requestedfrom the past.

In particular, the present disclosure provides an interconnection memberand a battery module including the interconnection member, wherein theinterconnection member occupies a small space in the battery modulebecause of its simple wiring structure, and is capable of sensing atemperature of the battery cell.

Technical Solution

In accordance with an exemplary embodiment, an interconnection memberfor connecting bus bars which are coupled to a printed circuit board(PCB) of a battery module and electrode terminals of battery cells, theinterconnection member includes: (a) a main cable made of a flexibleflat cable (FFC) including a plurality of copper wires; (b) a pluralityof terminal parts branched from the main cable and electricallyconnected to at least one of the copper wires of the main cable, theplurality of terminal parts being connected to the bus bars to sensevoltages of the battery cells; (c) a connecting part formed on one-sideend of the main cable, and electrically and mechanically connected tothe PCB; and (d) at least one temperature sensing part branched from themain cable, adjacent to the connecting part, while sharing at least oneof the copper wires of the main cable, wherein at least two of (b) to(d) are made of an FFC.

That is, the interconnection member in accordance with the presentdisclosure includes connecting connectors for a voltage sensing part,the temperature sensing part, and the PCB, each of which has a wiringstructure. The connecting connector is integrally formed with the maincable as a structure extending and branched from the main cable, so thatthe wiring structure becomes compact.

Particularly, the main cable is made of the FFC that is extremely thinand lightweight, and thus there is no need to prepare a separate spaceand a plurality of fastening members such as screws, bolts, rivets, andcoupling arms, for installing the interconnection member. In oneexample, the interconnection member is fixed in such a manner that themain cable is attached to some surfaces of the battery cell or a modulecase by means of insulating tape, to thereby achieve excellent spaceutilization and deletion of components required for coupling.

In addition, the connecting part may be made of an FFC so as to beelectrically and mechanically coupled to an FFC connector provided inthe PCB. The connecting part may extend from the main cable whilesharing all the copper wires of the main cable. This also, as describedabove, may achieve better space utilization of the interconnectionmember and significantly reduce the number of components required forinstallation.

As described above, the terminal parts and the temperature sensing partsbranched from the main cable should be short-circuited to each other sothat the terminal parts and the temperature sensing parts haveindependent current circuits respectively. Therefore, in the presentdisclosure, the copper wires respectively shared by the terminal partsand the terminal parts may be short-circuited to each other.

In a specific example, the temperature sensing part may includes: afirst extending part extending from the main cable while sharing atleast one copper wire of the main cable; and a ceramic thermistordisposed on an end of the first extending part while being electricallyconnected to the first extending part.

In this case, the first extending part may be made of an FFC, and theceramic thermistor may be attached to an outer surface of the batterycell. This also, as described above, may achieve better spaceutilization of the interconnection member and significantly reduce thenumber of components required for installation.

In this configuration, a temperature may be sensed by detecting a changein current that flows from the ceramic thermistor to the PCB via theextending part, and the connecting part.

In one specific example, each of the terminal parts may include: asecond extending part that extends from the main cable; and a contactpart that is electrically connected to the second extending part andcontacts a voltage sensing terminal provided in the bus bar.

As an exemplary embodiment, the second extending part may be an FFC thatextends from the main cable while sharing at least one copper wire ofthe main cable.

The exemplary embodiment, as described above, may maximize the spaceutilization by using the FFC having the thin thickness and may be simplyattached by means of the insulating tape. Therefore, the spaceutilization of the interconnection member for the battery module may bemaximized.

In addition, because of flexibility of the FFC, a wiring structure maybe designed to be a compact size. It is more preferable when electrodeterminals, which are connected to the terminal parts, of the batterycells are positioned in one direction.

Alternatively, as another exemplary embodiment, the second extendingpart may be a wire coupled to at least one copper wire of the main cableby means of soldering.

In another exemplary embodiment as described above, the second extendingpart is made of a wire having high durability, and thus may be connectedto the main cable while having a longer length. In other words, it ispreferable in the case that the main cable is remote far from thebattery cells due to a large size of the battery module. In addition,this wiring structure may be appropriate to the case that a wiringlength becomes longer when the electrode terminals of the battery cellsare disposed in several directions.

The contact part may have a ring shape so that the contact part isinserted and fastened to the voltage sensing terminal in a rivetingmanner. Through this riveting manner, a rivet of the voltage sensingterminal is fastened to the inside of the contact part to achievemechanical and electrical coupling.

As another example, the contact part may be made of a plate-shaped plateso that the contact part is inserted and fastened to the voltage sensingterminal in a clamping manner.

The clamping manner may mean that voltage sensing terminals are pressedand deformed, in a state in which the contact part is disposed betweenthe voltage sending terminals, to be mechanically fastened to thecontact part.

In addition, the contact part may be made of a ring- or plate-shapedmetal plate so that the contact part is coupled to the voltage sensingterminal by means of soldering or laser welding.

In another exemplary embodiment, a first clamping part may be coupled tothe main cable in a clamping manner, as a configuration in which thesecond extending part is electrically connected to the copper wires ofthe main cable, and the contact part may include: branched wires whichare branched from an end of the first clamping part; a second clampingpart coupled to the branched wires in a clamping manner; and aplate-shaped plate contacting end which extends from the second clampingpart and through which the contact part is coupled to the voltagesensing terminal by means of soldering or laser welding.

The clamping manner may mean that the first clamping part is physicallypressed to accommodate the main cable therein, and this may be equallyapplied to the second clamping part and the branched wires.

The present disclosure also provides a battery module and a deviceincluding the battery module.

The battery module may include: a module laminated body in which atleast two battery cells are laterally arranged; and a bus bar assemblythat electrically connects electrode terminals of battery cells disposedon the front surface of the module laminated body.

In one specific example, the bus bar assembly may include: bus barsrespectively coupled to the electrode terminals of the battery cells;and a main frame on which the bus bars are fixed and the PCB is mounted.

The interconnection member of the present disclosure may be fixed to themodule laminated body in such a manner that the main cable is attached,along an outer surface of the module laminated body, by means of aninsulating film or an adhesive.

That is, the main cable of the present disclosure is made of the FFCthat is extremely thin and lightweight, and thus there is no need toprepare a separate space and a plurality of fastening members such asscrews, bolts, rivets, and coupling arms, for installing theinterconnection member. Therefore, a battery module with a more compactstructure may be provided.

The device, for example, may include, but not limited to, laptopcomputers, netbooks, tablet personal computers, mobile phones, MP3players, wearable electronic devices, power tools, electric vehicles(EVs), hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles(PHEVs), electric bicycles (E-bikes), electric scooters (E-scooters),electric golf carts, or power storage systems.

Since structures and manufacturing methods of these devices are wellknown in the art, detail descriptions thereof will be omitted in thisdisclosure.

Advantageous Effects

As described above, an interconnection member of the present disclosureincludes connecting connectors for a voltage sensing part, a temperaturesensing part, and a PCB, each of which has a wiring structure. Theconnecting connector is integrally formed with a main cable as astructure extending and branched from the main cable, so that a wiringstructure becomes compact.

Particularly, the main cable is made of the FTC that is extremely thinand lightweight, and thus there is no need to prepare a separate spaceand a plurality of fastening members such as screws, bolts, rivets, andcoupling arms, for installing the interconnection member.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of an interconnection member in accordancewith an exemplary embodiment.

FIG. 2 is a schematic view of an exemplary connection between aconnecting part and a PCB connector of a PCB;

FIG. 3 is a schematic view of a temperature sensing part.

FIG. 4 is a schematic view of an interconnection member in accordancewith another exemplary embodiment.

FIG. 5 is a schematic view showing a bonded shape of a main cable andsecond extending parts.

FIG. 6 is a schematic view showing a portion of an interconnectionmember in accordance with another exemplary embodiment.

FIG. 7 is a schematic view showing a portion of a battery module inaccordance with an exemplary embodiment including the interconnectionmember of FIG. 6.

FIG. 8 is a schematic view of a battery module in accordance withanother exemplary embodiment.

MODE FOR CARRYING OUT THE INVENTION

Hereinafter, although the present disclosure is described with referenceto the drawings in accordance with exemplary embodiments, this isintended to provide a further comprehension of the present disclosure,and the scope of the present disclosure is not limited thereto.

FIG. 1 illustrates a schematic view of an interconnection member inaccordance with an exemplary embodiment.

Referring to FIG. 1, an interconnection member 100 includes a main cable110 made of a flexible flat cable (FFC) having a plurality of copperwires, terminal parts 120, a connecting part 130 disposed on an end ofthe main cable 110, and a temperature sensing part 140.

Each of the terminal parts 120 includes a second extending part 124 thatextends from the main cable 110, and a contact part 122 that iselectrically connected to the second extending part 124 and contacts avoltage sensing terminal disposed in the bus bar.

The second extending parts 124 extends from one-side end of the maincable 110 while being spaced apart from each other at a predetermineddistance, and also extends from the other end thereof while being spacedapart from each other at a predetermined distance, resulting in anapproximately symmetrical configuration based on the main cable 110.This is merely one exemplary embodiment, so the second extending parts124 may be asymmetrically arranged depending on an arrangement type ofthe battery cells.

Each of the second extending parts 124 includes an FFC that extends fromthe main cable 110, while having at least one copper wire of the maincable 110.

That is, the terminal parts 120 connected to the battery cells are madeof the FFC having a thin thickness. Therefore, space utilization of theinterconnection member 100 may be maximized within the battery module,and an assembling process for the battery module may be simplifiedthrough a structure that is easily fixed by means of insulating tape andthe like.

The contact part 122 has a ring shape so as to be inserted and fastenedto the voltage sensing terminal in a riveting manner. The rivetingmanner, for example, means a configuration in which a rivet of thevoltage sensing terminal is fastened to the inside of a ring of thecontact part 122 to achieve mechanical and electrical coupling.

The connecting part 130 is a terminal of the main cable 110, which iselectrically and mechanically coupled to an FFC connector provided on aPCB 10, and is made of an FFC as in the main cable 110. The connectingpart 130 extends from the main cable 110, while sharing all the copperwires of the main cable 110.

In regard to this configuration, FIG. 2 illustrates a view of anexemplary connection between the connecting part and the FTC connectorof the PCB 10.

The connecting part 130 may achieve the mechanical and electricalcoupling between the interconnection member 100 and the PCB 10, with aconvenient configuration in which the FFC having the thin thickness isinserted into a connector 12 of the PCB 10, when compared to aconfiguration in which the connecting part 130 is coupled on the PCB 10by means of welding and the like.

The temperature sensing part 140 includes a first extending part 142that extends from the main cable 110 while sharing at least one copperwire of the main cable 110, and a ceramic thermistor 144 provided on anend of the first extending part 142 while being electrically connectedto the first extending part 142.

In regard to this configuration, FIG. 3 illustrates a schematic view ofthe temperature sensing part 140.

Referring to FIG. 3, the first extending part 142 is made of an FFC, andthe ceramic thermistor 144 may be attached to an outer surface of thebattery cell. Therefore, through this configuration, better spaceutilization of the interconnection member 100 may be achieved, and thenumber of components required for installation may be significantlyreduced.

The temperature sensing part 140 may sense a temperature by detecting achange in current that flows from the ceramic thermistor 144 to the PCB10 via the extending part and connecting part 130.

FIG. 4 illustrates an interconnection member in accordance with anotherexemplary embodiment.

Referring to FIG. 4, an interconnection member 200 is similar to theinterconnection member 100 of FIG. 1, except for a structure of aterminal part 220. Hereinafter, the structure of the terminal part 200will be described in conjunction with FIG. 5 illustrating an image inwhich a main cable 210 is bonded to second extending parts 224.

Each of the terminal parts 200 includes a second extending part 224 thatextends from the main cable 210, and a contact part 222 that iselectrically connected to the second extending part 224 and contacts avoltage sensing terminal disposed a bus bar. The second extending parts224 include wires respectively coupled to copper wires of the main cable210 by means of soldering.

Such a structure may be connected to the main cable 210, with a longerlength, because a wire itself has high durability. Particularly, thismay be preferable in case that the main cable 210 is remote far from thebattery cells due to a large size of the battery module.

Referring to FIG. 6, an interconnection member is similar to theinterconnection member of FIG. 1 or FIG. 4, except for a structure of aterminal part. That is, the structure of the terminal part is differentfrom the foregoing structures.

In particular, the terminal part 320 of the interconnection memberincludes a second extending part that extends from a main cable 310, anda contact part 330 that is electrically connected to the secondextending part and contacts a voltage sensing terminal provided in thebus bar.

In this case, a first clamping part 324 is coupled to the main cable 310in a clamping manner, as a configuration in which the second extendingpart is electrically connected to the copper wires of the main cable310.

The contact part 330 includes branched wires 332 b branched from an endof the first clamping part 324, a second clamping part 332 c coupled tothe branched wires 332 b in a clamping manner, and a plate-shaped platecontacting end 332 a which extends from the second clamping part 332 cand through which the contact part 330 is coupled to the voltage sensingterminal by means of soldering or laser welding.

In regard to this structure, FIG. 7 illustrates a schematic view showinga portion of a battery module in accordance with an exemplaryembodiment, including the interconnection member of FIG. 6.

Referring to FIG. 7 in conjunction with FIG. 6, the main cable 310 ofthe interconnection member is fixed to a module laminated body in such amanner that the main cable 310 is attached to an insulating film alongthe module laminated body, and the first clamping part 324 of theterminal part 320 is coupled to an end of the main cable 310.

In the terminal part 320, the branched wires 332 b are branched from thefirst clamping part 324, and the contact part 330 including theplate-shaped plate contacting end 332 a, which extends from the secondclamping part 332 c, includes the second clamping part 332 c in aclamping manner, and thus the second clamping part 332 c is coupled tothe branched wires 332 b.

Each of the contact ends 332 a of the contact part 330 is coupled to avoltage sensing terminal 442 of a bus bar assembly, and this couplingmay be achieved by means of, for example, soldering, ultrasonic welding,laser welding, resistance welding, and the like.

Also, FIG. 8 illustrates a schematic view showing a battery module inaccordance with an exemplary embodiment.

Referring to FIG. 8, a battery module 300 includes an interconnectionmember 330, a module laminated body 310 in which battery cells arelaterally arranged, and a bus bar assembly 320 that electricallyconnects electrode terminals, which are disposed on the front and rearsurface of the module laminated body 310, of the battery cells.

The bus bar assembly 320 includes bus bars 322 respectively coupled tothe electrode terminals of the battery cells, and a main frame 326 onwhich the bus bars 322 are fixed and a PCB 324 is mounted.

In this case, the interconnection member 330 is fixed to the modulelaminated body 310 in such a manner that a main cable is attached by aninsulating film along an outer surface of the module laminated body 310,and a connecting part disposed on one-side end of the interconnectionmember 330 comes into contact with the PCB 324.

That is, the main cable of the present disclosure is made of the FFCthat is extremely thin and lightweight, and thus there is no need toprepare a separate space and a plurality of fastening members such asscrews, bolts, rivets, and coupling arms, for installing theinterconnection member. Therefore, a battery module with a more compactstructure may be provided.

It will be apparent, by those skilled in the art to which the presentdisclosure pertains, that various applications and modifications can bemade thereto, on the basis of the above-descriptions, within the scopeof the present disclosure.

1. An interconnection member for connecting bus bars which a coupled toa printed circuit board (PCB) of a battery module and electrodeterminals of battery cells, the interconnection member comprising: (a) amain cable made of a flexible flat cable (FFC) including a plurality ofcopper wires; (b) a plurality of terminal parts branched from the maincable and electrically connected to at least one of the copper wires ofthe main cable, the plurality of terminal parts being connected to thebus bars to sense voltages of the battery cells; (c) a connecting partformed on one-side end of the main cable, and electrically andmechanically connected to the PCB; and (d) at least one temperaturesensing part branched from the main cable, adjacent to the connectingpart, while sharing at least one of the copper wires of the main cable,wherein at least two of (b) to (d) are made of an FFC.
 2. Theinterconnection member of claim 1, wherein the copper wires of the maincable, which are respectively shared by the terminal parts and thetemperature sensing parts, are short-circuited to each other.
 3. Theinterconnection member of claim 1, wherein the connecting part is madeof an FFC so as to be electrically and mechanically coupled to an FFCconnector provided in the PCB.
 4. The interconnection member of claim 1,wherein the temperature sensing part comprises: a first extending partextending from the main cable while sharing at least one copper wire ofthe main cable; and a ceramic thermistor disposed on an end of the firstextending part while being electrically connected to the first extendingpart.
 5. The interconnection member of claim 4, wherein the firstextending part is made of an FFC, and the ceramic thermistor is attachedto an outer surface of the battery cell.
 6. The interconnection memberof claim 5, wherein a temperature is sensed by detecting a change incurrent that flows from the ceramic thermistor to the PCB via theextending part and the connecting part.
 7. The interconnection member ofclaim 1, wherein the connecting part extends from the main cable whilesharing all the copper wires of the main cable.
 8. The interconnectionmember of claim 1, wherein each of the terminal parts comprises: asecond extending part that extends from the main cable; and a contactpart that is electrically connected to the second extending part andcontacts a voltage sensing terminal provided in the bus bar.
 9. Theinterconnection member of claim 8, wherein the second extending part isan FFC that extends from the main cable while sharing at least onecopper wire of the main cable.
 10. The interconnection member of claim8, wherein the second extending part is a wire coupled to at least onecopper wire of the main cable by means of soldering.
 11. Theinterconnection member of claim 8, wherein the contact part has a ringshape so that the contact part is inserted and fastened to the voltagesensing terminal in a riveting manner.
 12. The interconnection member ofclaim 8, wherein the contact part is made of a plate-shaped plate sothat the contact part is inserted and fastened to the voltage sensingterminal in a clamping manner.
 13. The interconnection member of claim8, wherein, through the clamping manner, voltage sensing terminals arepressed and deformed, in a state in which the contact part is disposedbetween the voltage sending terminals, to be mechanically fastened tothe contact part.
 14. The interconnection member of claim 8, wherein thecontact part is made of a ring- or plate-shaped metal plate so that thecontact part is coupled to the voltage sensing terminal by means ofsoldering or laser welding.
 15. The interconnection member of claim 8,wherein a first clamping part is coupled to the main cable in a clampingmanner, as a configuration in which the second extending part iselectrically connected to the copper wires of the main cable, and thecontact part comprises: branched wires which are branched from an end ofthe first clamping part; a second clamping part coupled to the branchedwires in a clamping manner; and a plate-shaped plate contacting endwhich extends from the second clamping part and through which thecontact part is coupled to the voltage sensing terminal by means ofsoldering or laser welding.
 16. A battery module comprising: theinterconnection member of claim 1; a module laminated body in which atleast two battery cells are laterally arranged; and a bus bar assemblythat electrically connects electrode terminals of battery cells disposedon the front surface and/or the rear surface of the module laminatedbody.
 17. The battery module of claim 16, wherein the bus bar assemblycomprises: bus bars respectively coupled to the electrode terminals ofthe battery cells; and a main frame on which the bus bars are fixed andthe PCB is mounted.
 18. The battery module of claim 16, wherein theinterconnection member is fixed to the module laminated body in such amanner that the main cable is attached, along an outer surface of themodule laminated body, by means of an insulating film or an adhesive.19. A device comprising the battery module of claim 16.